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Table of contents for the manual
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Page 1
PO WER W A VE A C/DC ™ OPERA TOR’S MANUAL IM718 June 2002 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING TH[...]
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FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]
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ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]
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FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]
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iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]
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Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]
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vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications - POWER WAVE AC/DC ...............................................A-1 Safety Precautions.................................................................................[...]
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A-1 INST ALLA TION POWER WAVE AC/DC A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE AC/DC (K1860-1) OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERA TURE RANGES INPUT A T RA TED OUTPUT - THREE PHASE ONL Y INPUT VOLTS 50/60HZ. 3 PHASE 460/500/575V OPEN CIRCUIT VOLTAGE 90VDC INPUT VOLTAGE / FREQUENCY 50/60HZ 460V 500V 575V HEIGHT[...]
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LIFTING Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave with accessories attached to it. ST ACKING Power Wave AC/DC machine cannot be stacked. MACHINE GROUNDING The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside t[...]
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A-3 INST ALLA TION POWER WAVE AC/DC A-3 INPUT CONNECTION Only a qualified electrician should connect the input leads to the Power Wave. Connections should be made in accordance with all local and national electrical codes and the connection dia- gram located on the inside of the reconnect/input access door of the machine. Failure to do so may resul[...]
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A-4 INST ALLA TION POWER WAVE AC/DC A-4 WELDING WITH MUL TIPLE UNSYN- CHRONIZED POWER W A VES Special care must be taken when more than one Power Wave is welding unsynchronized on a sin- gle part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead to the work stud to the welding fixture. Do not combine a[...]
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A-5 INST ALLA TION POWER WAVE AC/DC A-5 MUL TIPLE UNSYNCHRONIZED ARC SENSE LEAD AND WORK LEAD PLACEMENT GUIDELINES Wor k # 2 Se ns e # 2 Pow er Source #2 Pow er Sourc e #1 Arc # 1 Arc #2 Wor k #1 Se ns e # 1 Work # 2 Power Source #2 Powe r Source #1 A rc #1 A rc #2 Work # 1 Sens e # 1 Se n se # 2 Current Flow Pow er Source #1 Pow er Source #2 Work [...]
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A-6 INST ALLA TION POWER WAVE AC/DC A-6 ELECTRODE AND WORK CABLE CONNECTIONS Due to the PowerWave AC/DC ’ s ability to produce either a DC positive, DC negative or AC output the electrode and work connections do not need to be reversed for the different polarities. Additionally no DIP switch changes are required to switch between the different po[...]
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VOL T AGE SENSING The best arc performance occurs when the PowerWave AC/DC has accurate data about the arc conditions. Depending upon the process, inductance within the electrode and work lead cables can influ- ence the voltage apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc conditions and can have a dramati[...]
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CONTROL CABLE CONNECTIONS BETWEEN POWER SOURCE AND WIREFEEDER Connect the control cable between the power source and wire feeder. The wire feeder connection on the PowerWave AC/DC is located under the spring loaded output cover, on the case front. The control cable is keyed and polarized to prevent improper connect. For convenience, the control cab[...]
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EXTERNAL I/O CONNECTOR The Power Wave is equipped with a terminal strip for making simple input signal connections. The terminal strip is located underneath the spring-loaded cover. It is divided into three groups: Trigger group, Cold Inch Group and Shutdown Group. Because the Power Wave is a ‘ slave ’ on the DeviceNet network, the Trigger and [...]
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A-10 INST ALLA TION POWER WAVE AC/DC A-10 DIP Switch Settings and Locations DIP switches on the P.C. Boards allow for custom configuration of the Power Wave. To access the DIP switches: • Turn off power at the disconnect switch. ------------------------------------------------------------------------ • Remove the top four screws securing the fr[...]
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A-11 INST ALLA TION POWER WAVE AC/DC A-11 DEVICENET MAC ID TABLE A.5 Mac I.D. Switch 8 Switch7 Switch6 Switch5 Switch4 Switch 3 0 0 0 0 0 0 0 Software Selectable 1000001 2000010 3000011 4000100 5000101 6000110 7000111 8001000 9001001 1 0 001010 1 1 001011 1 2 001100 1 3 001101 1 4 001110 1 5 001111 1 6 010000 1 7 010001 1 8 010010 1 9 010011 2 0 01[...]
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A-12 INST ALLA TION POWER WAVE AC/DC A-12 Bank S3 and S4[...]
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A-13 INST ALLA TION POWER WAVE AC/DC A-13 MUL TI-ARC SYSTEM DESCRIPTION The following is a general description of how the PowerWave AC/DC can be configured in a multi-arc set-up. Each welding arc may be driven by one machine or up to four machines connected in parallel. The hardware for the power source has been designed so that the power source ca[...]
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B-1 OPERA TION B-1 POWER WAVE AC/DC SAFETY PRECUA TIONS Read this entire section of operating instructions before operating the machine. ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always elec- trically energized and could remain energized several seconds after th[...]
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B-2 OPERA TION B-2 POWER WAVE AC/DC INPUT POWER ON OFF HIGH TEMPERA TURE MACHINE ST A TUS CIRCUIT BREAKER WIRE FEEDER POSITIVE OUTPUT NEGA TIVE OUTPUT 3 PHASE INVERTER INPUT POWER THREE PHASE DIRECT CURRENT GMA W FCA W GT A W OPEN CIRCUIT VOL T AGE INPUT VOL T AGE OUTPUT VOL T AGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND W ARNING GRAPHIC SYMB[...]
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B-3 OPERA TION B-3 POWER WAVE AC/DC DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will select the cor- rect voltage and amperage based[...]
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RECOMMENDED EQUIPMENT /INTERF ACE Robotic Operation All welding programs and procedures are configured through software for the robotic Power Waves. With the proper configuration, Fanuc robots equipped with RJ-3 or RJ-3iB controllers may communicate directly to the Power Wave via ArcLink or DeviceNet. Proper configuration and options allow other eq[...]
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B-5 OPERA TION POWER WAVE AC/DC B-5 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) 1 . POWER SWITCH: Controls input power to the Power Wave. 2. STATUS LIGHT: A two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indi[...]
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B-6 OPERA TION B-6 POWER WAVE AC/DC Second, find the program in the welding software that best matches the desired welding process. The stan- dard software shipped with the Power Waves encom- passes a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales repre- sen[...]
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B-7 OPERA TION B-7 CV WELDING Synergic CV: For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special soft- ware at the factory. The nominal preprogrammed volt- age is the best average voltage for a given wire feed speed, but may be adjusted to preference. With syner- gic programs, when the wire feed speed c[...]
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B-8 OPERA TION B-8 PULSE WELDING Pulse welding procedures are set by controlling an overall "arc length" variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed [...]
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C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT F ACTOR Y INST ALLED There are no factory installed options available for the Power Wave. FIELD INST ALLED OPTIONS / ACCESSORIES Required Accessories For Paralleling machines • Control Cables (22 pin to 22 pin), K1795-10,-25,-50,-100 In Robotic Applications • Control Cables (for use on FANUC robot arm, 22 [...]
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D-1 MAINTENANCE D-1 POWER WAVE AC/DC SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only Qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE MAINTENANCE Routine maintenance consists of periodically b[...]
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E-1 TROUBLESHOOTING E-1 POWER WAVE AC/DC If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair[...]
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E-2 TROUBLESHOOTING E-2 POWER WAVE AC/DC Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. PROBLEMS (SYMPTOMS) POSSIBLE A[...]
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E-3 TROUBLESHOOTING E-3 POWER WAVE AC/DC Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. PROBLEMS (SYMPTOMS) POSSIBLE A[...]
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E-4 TROUBLESHOOTING E-4 POWER WAVE AC/DC Observe all Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact your local authorized Lincoln Electric Field Service Facility for technical assistance. PROBLEMS (SYMPTOMS) POSSIBLE A[...]
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E-5 TROUBLESHOOTING E-5 POWER WAVE AC/DC Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLE[...]
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E-6 TROUBLESHOOTING E-6 POWER WAVE AC/DC USING THE ST A TUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The Power Wave is equipped with a status light if a problem occurs it is important to note the condition of the status light.Therefore, prior to cycling power to the system, check the power source status light for error sequences as noted below. Included[...]
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E-7 TROUBLESHOOTING E-7 POWER WAVE AC/DC Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ERROR [...]
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F-1 DIAGRAMS F-1 POWER WAVE AC/DC NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code nu[...]
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F-2 DIAGRAMS F-2 POWER WAVE AC/DC NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code nu[...]
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F-3 PIN, LEAD CONNECT OR SETUPS F-3 POWER WAVE AC/DC T ABLE F .5 DEVICENET CONNECT OR S5 Pin Lead # Function 2 894 +24vdc Devicenet 3 893 Commom Devicenet+ 4 892 Devicenet H 5 891 Devicenet L T ABLE F .2 WIRE FEEDER RECEPT ACLE S1 Pin Lead # Function A 53 Arclink L B 54 Arclink H C 67A Electrode V oltage Sense D 52 Ground(0v) E 51 +40vdc T ABLE F .[...]
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F-4 CONNECTION DIAGRAM F-4 POWER WAVE AC/DC K1796 COAXIAL WELD CABLE User supplied work lead User supplied electrode lead - + PO WER W A VE CONTROL CABLE K1805-1 WORK SENSE LEAD K940 DEVICENET CABLE K1804-1 CONTROL CABLE OR K1804-2 AND ANY K1795 CONTROL CABLE Use r sup p lie d wor k le ad Us er s u ppl ied e l ec t r od e l ea d CO NTRO L CA B LE K[...]
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F-5 DIMENSION PRINT F-5 POWER WAVE AC/DC XA 9.45 19.16 19.83 14.62 37.46 18.80 33.08 .65 .96 34.96 L1 1656[...]
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NOTES POWER WAVE AC/DC[...]
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NOTES POWER WAVE AC/DC[...]
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Now A vailable...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay. Place your order now using the coupon below. The hardbound book conta[...]
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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA E[...]
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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]
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• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]